Joinery member and fastener and process and apparatus for placement of the fastener

ABSTRACT

A device ( 41 ) for positioning a joinery fastener ( 74 ) in a joinery member ( 33 ) for later use in forming a joinery assembly. The fastener positioning device ( 41 ) includes a feed magazine ( 82 ) formed for feeding joinery fasteners ( 74 ) to a gripping apparatus ( 83 ). The gripping apparatus ( 83 ) is positioned to receive the fasteners ( 74 ) and is further adapted to releasably grip individual fasteners ( 74 ) at a position ( 103 ) below the fastener head ( 86 ) to hold the fasteners ( 74 ) in a known and controlled, indexed relation to the gripping apparatus ( 83 ). The gripping apparatus is movable between a fastener gripping position to a fastener placement position while the pointed end ( 88 ) of the fastener ( 74 ) remains in indexed relation, and a placement arm ( 92 ) is formed to urge the fastener ( 74 ) from the gripping apparatus ( 83 ) and into interference fit with the joinery member ( 33 ). A joinery member ( 33 ) having a fastener ( 74 ) mounted in interference fit with a bore ( 68 ) therein is also disclosed, as is a preferred form of pocket screw fastener ( 74 ), a fastener-receiving bore ( 68 ) with an elongated transverse cross section and a process for automatically positioning fasteners ( 74 ) in joinery members ( 33 ) for later joining to another member.

TECHNICAL FIELD

[0001] The present invention relates, in general, to joinery memberswhich are secured together using fasteners, such as wood screws, andmore particularly, relates to pocketed joinery members and thepositioning of the wood screws in the screw pockets for subsequentsecurement of the joinery member to a second member.

BACKGROUND ART

[0002] Many commercially manufactured cabinet and furniture products areformed from a plurality of wooden, composite or plastic members whichare joined together by a plurality of fasteners, most usually woodscrews. In many instances, the wood screws are positioned in screwpockets or mortises formed in the joinery member adjacent to an edge ofthe member, which edge is then secured to a second joinery member.

[0003] A typical prior art cabinetry or furniture joint is shown inFIG. 1. A first joinery member 21 is shown in abutting relation to asecond member 22. First and second members 21 and 22 are securedtogether by a fastener, in this case a wood or pocket screw 23, which ismounted in a pocket 24 in the first joinery member. A bore 26 extendsfrom edge 27 of the first joinery member to pocket 24, and screw 23 ispositioned in bore 26 and screwed into the second joinery member 22 tosecure the assembly together as a unit. Typically, a plurality offasteners 23 will be used along the length of the two members beingjoined, and second member 22 may be provided with pre-drilled holes orbores which receive the screws and make driving of the same easier.Pocketed securement together of two joinery members is often employed tojoin face frames of various structures, but it also can be employed tosecure panels together and combinations of panels and frame members.

[0004] The formation of screw pocket 24 can be accomplished usingvarious types of equipment. One of the most efficient ways of formingpocket 24 and bore 26, however, is set forth in my U.S. Pat. No.4,603,719. Subsequently I have devised a hand-held screw pocket formingapparatus, which is shown in my U.S. Pat. No. 5,063,982, and pocket ormortise inserts are shown in my U.S. Pat. No. 4,944,627.

[0005] If the number of members to be joined together is relativelysmall, the apparatus of U.S. Pat. No. 4,603,719 and 5,063,982 can beemployed, and the wood working fabricator can manually place fastenersor pocket screws 23 into pockets 26. In the do-it-yourself or low volumecontexts, therefore, it is relatively easy and not too time consuming tosimply manually position the pocket screws for screwing into the otherjoinery member using a powered or unpowered screwdriver.

[0006] In high production situations, however, fabrication lines need tobe partially or fully automated, and one of the most difficult tasks ina joinery production line is to automate the positioning of fasteners inthe joinery members so that they can be fastened together using a powerscrewdriver. It is highly undesirable in high production applications,therefore, to form the pocket 24 and bore 26 automatically and yet haveto employ manual labor to insert fasteners in the bores for subsequentpowered screwing together of the joinery pieces.

[0007] Several problems are encountered which make automating a joineryproduction line difficult. One is the need to move the joinery membersduring the process. Such movement will tend to cause fasteners tovibrate or fall out of the pockets before they can be screwed intoanother member to join the two members together. Another problem is theneed to control the orientation and location of the pointed ends of thefasteners or pocket screws. Thus, automated placement of wood screws insmall diameter bores, such as bore 26, can be difficult. Such placementrequires that the pocket screw pointed end be aligned with the borewithin relatively close tolerances so that the fastener will not bejammed into the end wall of the pocket adjacent to bore 26 and therebyshut down the production line.

[0008] While existing pocket screws are suitable for use in highproduction applications, using the apparatus and process of the presentinvention, such conventional pocket screws or wood screws are not formedin a manner which makes them ideal for the present process andapparatus. Moreover, conventional screw pocket forming apparatus,including my prior U.S. Pat. Nos. 4,603,716 and 5,063,982, producepockets or mortises having a screw receiving bore 26 which also issomewhat less than ideal for use in the present apparatus and process.

[0009] Accordingly, it is an object of the present invention to providean apparatus and process for automated placement of fasteners, andparticularly pocket screws, into joinery members for subsequentfastening together of the joinery members in a high production setting.

[0010] A further object of the present invention is provide an improvedpocket screw construction which enhances placement of the pocket screwsin joinery members in a production line for subsequent formation ofjoinery assemblies.

[0011] Still a further object of the present invention is to provide animproved pocket screw which is better suited for joining pocketedjoinery members.

[0012] The process, apparatus and resulting joinery member of thepresent invention have other objects and features of advantage whichwill become apparent from, or are set forth in more detail in, theaccompanying drawing and following Best Mode of Carrying Out theInvention.

DISCLOSURE OF INVENTION

[0013] In one aspect of the present invention, a joinery member having afastener pocket and a fastener positioned in the pocket is provided. Thejoinery member has a fastener pocket formed therein proximate an edge ofthe member and a fastener-receiving bore extending from the pocket to anedge of the member. A fastener, having a shank portion, is mounted inthe pocket with the shank portion mounted in interference fit with thefastener-receiving bore to retain the fastener in the pocket beforesecuring the fastener to a second joinery member. Most preferably, thefastener is mounted in the pocket in a position entirely inwardly of thesurface of the joinery member in which the pocket is formed and entirelyinwardly of the edge to which the fastener-receiving bore extends.

[0014] In another aspect, a process for forming a joinery assembly isprovided which comprises, briefly, of the steps of forming afastener-receiving bore in the joinery member; and thereafter mounting ajoinery fastener, having a point end, in the fastener pocket with thepointed end of the fastener extending into the bore and the fastenerbeing frictionally secured in interference fit with the bore, mostpreferably by a shank portion of the fastener. The process preferably isaccomplished by first forming a fastener pocket in a surface of thejoinery member proximate and spaced from an edge thereof and thenforming the bore to extend between the pocket and the edge.

[0015] In a further aspect of the present invention, a joinery pocketscrew is provided which comprises, briefly, a monolithic screw bodyformed with a head, a shank extending away from the head and a threadedpointed end extending away from the shank. The shank has a shankdiameter greater than the widest diameter of the threaded end, and thehead is formed with a plurality of annular steps of increasing diametersstepping outwardly from the shank.

[0016] An additional aspect of the present invention is to provide ajoinery member having a non-cylindrical fastener-receiving bore with anoval cross section in which a large diameter extends across a relativelysmall thickness dimension of a joinery member and the small diameter issubstantially perpendicular thereto that extends along a relativelylarge width dimension of the joinery member.

[0017] A process for positioning a fastener in a joinery member forsubsequent securement to a second joinery member also is provided. Thefastener has a head, a body and a distal end for securement to thesecond member. The fastener placement process is suitable for automated,high production apparatus and is comprised, briefly, of the steps offeeding the fastener to a gripping apparatus; manipulating the fastenerto a known orientation; gripping the body of the fastener while in theknown orientation with the gripping apparatus; moving the grippedfastener to a fastener placement position proximate the joinery memberwhile maintaining the fastener in the known orientation; and displacingthe fastener from the placement position into contact with the joinerymember for securement to the joinery member.

[0018] Finally, a joinery fastener positioning device is provided whichcomprises, briefly, a positioning surface for positioning a joinerymember in a known position for placement of a joinery fastener incontact with the joinery member; a feed magazine formed for feedingpointed joinery fasteners to gripping apparatus; a gripping apparatuspositioned to receive fasteners from the feed magazine, the grippingapparatus being further adapted to releasably grip individual fastenersin a manner causing the pointed end of the fastener to be held in aknown and controlled indexed relation to the gripping apparatus, and thegripping apparatus being movable between a fastener-receiving positionand a fastener placement position while the pointed end of the fastenerremains in indexed relation to the gripping apparatus; and a fastenerplacement assembly formed to urge the fastener from the grippingapparatus into contact with the joinery member, preferably into a borein the joinery member, with the pointed end of the fastener in apredetermined, known position in relation to the joinery member.

DESCRIPTION OF THE DRAWING

[0019]FIG. 1 is a fragmentary, side elevation view, in cross section oftwo joinery members secured together by a pocket screw as is known inthe prior art.

[0020]FIG. 2 is a top plan, schematic representation of an automatedproduction line suitable for use in securing together two joinerymembers and including screw pocket formation apparatus and automatedpocket screw placement apparatus constructed in accordance with thepresent invention.

[0021]FIG. 3 is an enlarged top plan schematic representation of thescrew pocket formation and fastener placement portion of the productionline of FIG. 2.

[0022]FIG. 4 is a schematic, side elevation view, in cross section, of ascrew pocket formation step.

[0023]FIG. 5 is a schematic, side elevation view, in cross section, of afastener-receiving bore formation step, showing the pocket formationapparatus in phantom.

[0024]FIG. 6 is a side elevation, schematic view, in cross section, of afastener positioning step in the process of the present invention.

[0025]FIG. 7 is a side elevation, schematic view, in cross section, of afastener placement step of the process of the present invention.

[0026]FIG. 8 is a side elevation view, broken away, of a joineryfastener placement device suitable for performing the steps of FIGS. 6and 7 to position fastener in a screw pocket.

[0027]FIG. 9 is an enlarged, fragmentary, side elevation view of afastener orienting assembly employed in the placement device of FIG. 8.

[0028]FIG. 10 is a top plan, fragmentary view of the orienting assemblyof FIG. 9.

[0029]FIG. 11 is an enlarged, fragmentary, side elevation view of afastener gripping assembly employed in the fastener placement device ofFIG. 8.

[0030]FIG. 12 is a fragmentary, end elevation view of the apparatus ofFIG. 11.

[0031]FIG. 13 is an enlarged, side elevation view, in cross-section, ofa preferred form of pocket screw fastener suitable for use in theprocess and with the apparatus of the present invention.

[0032]FIG. 14 is an enlarged, fragmentary, end elevation view of ajoinery member having a fastener-receiving bore constructed in a mannerpreferred for use with the present process and apparatus.

BEST MODE OF CARRYING OUT THE INVENTION

[0033] The process and apparatus of the present invention areparticularly well suited for partial or fully automated joineryapplications such as the production of components or subassemblies usedto form cabinetry or furniture. As used herein, the expression “joinerymember” shall include wooden members, composite resin and bondedcellulose-based and/or plastic members, plastic members, andcombinations of wood and plastic members. It is possible that thepresent apparatus and process also could be applied to metal members,particularly metals which are easily machined such as aluminum, butgenerally the present process and apparatus are best adapted for usewith materials typically employed in a production woodworking facilityto form products such as cabinetry and furniture. Moreover, the presentapparatus and method are particularly well suited for high productionruns in which manual steps are partially or fully automated so that acontinuous production line can be established. Such a production linecan be implemented by intermittently moving and stopping the joinerymembers at stationary processing stations or by continuously conveyingthe joinery members past reciprocating processing stations (jumpstations) which move with the member over a short distance. Obviously, acombination of intermittent movement of both the joinery member and/orthe processing equipment could also be employed, as can manual movementof members between processing stations.

[0034] Referring now to FIGS. 2 and 3, schematic representations of aprocessing line for the automatic joining together of two joinerymembers is shown. In the embodiment illustrated, the joinery members aremoving on a conveyor, generally designated 31, which carries the joinerymember past various processing equipment for the performance of thesteps necessary to join one member to a second member.

[0035] A typical production line might include, for example, a joinerymember feed station 32 at which members 33 are fed onto conveyor 31. Thefeed station can include member feeding apparatus 30 and an indexingstop or fence 34 which positions member 33 relative to conveyor 31. Aclamping assembly 36 clamps joinery member 33 to conveyor 31 aspositioned or indexed by fence 34 so that the subsequent processingapparatus can perform various operations on member 33 as it moves alongconveyor 31 in the direction of arrow 37. One type of clamping assembly36 which can be employed is seen in FIG. 8 in which a plurality ofdownwardly biased rollers 25 press on a low friction platen 35 (e.g. aDELRIN sheet), which in turn clamps down on moving belt 50 that engagesand displaces member 33. A low friction stationary surface 40 that issupported on conveyor frame member 55. Conveyor belt 50 returns above asecond low friction platen 60 above rollers 25. Other conveyors andclamping arrangements suitable for use in the present invention and arewell known in the art.

[0036] Once joinery member 33 is moving with conveyor 31 in indexrelation thereto, a first pocket forming station 38 may be provided,which preferably takes the form of a jump station. Pocket formingstation 38 will include apparatus 39, described in more detail below,which reciprocates parallel to conveyor 31 so as to process joinerymember 33 as it is being conveyed by conveyor 31. Processing isaccomplished during the stroke of the jump station 38 in the directionof arrow 37, while the pocket forming apparatus 39 is reciprocated backto a start position, shown in solid lines in FIGS. 2 and 3, before thenext joinery member reaches pocket forming station 38.

[0037] A fastener positioning apparatus, generally designated 41, ispositioned proximate conveyor 31 downstream of pocket forming apparatus39. At fastener-positioning station 43 fasteners, preferably pocketscrews, are positioned in the pocket formed at pocket forming station38. Again, it is preferable to employ a jump station approach atfastener-positioning station 43.

[0038] By the time joinery member 33 leaves the fastener positioningstation, the joinery member, will have one or more screw pockets formedin it and fastener screws positioned in the pockets for joining ofjoinery member 33 to another joinery member. At a joinery membermanipulation or rotation station 44, joinery member 33 can be releasedtemporarily from conveyor clamp 36 and repositioned, for example, byrotating as indicated by arrow 46. The repositioned joinery member isthen reclamped to the conveyor at clamping station 47 with the other endof member 33 in index relation to conveyor 31. Instead of rotatingjoinery member 33, it can also be released by clamping apparatus 36 andrepositioned for processing of the opposite end of the joinery member bya processing apparatus on the other side of conveyor 31 from the pocketapparatus 39 and the fastener positioning device 41.

[0039] Release and manipulation or repositioning of the joinery memberswill not be required if the line is set up to process joinery members ofexactly the same size. Length variations between joinery members,however, can be accommodated by the rotation or shifting and re-indexingof the opposite end of the member on the conveyor and re-clamping itwhile positioned against a stop. As illustrated in the FIG. 2, the linecontinues after manipulation station 44, and a second pocket formingstation 38 a, and a second fastener placement station 43 a may beprovided so that a pocket can be formed in the opposite end of member 33and a fastening screw placed in the pocket.

[0040] At station 48, a second joinery member 33 a can be conveyed by asecond conveyor 31 a onto conveyor 31, at which second member 33 a abutsfirst joinery member 33 in a desired predetermined relative orientation.Once placed in abutting position, the two joinery members are clampedand fastened at a fastening station 49, with fastening apparatus 51which fastens two joinery members 33, 33 a together. Thus, fasteningapparatus 51 can screw the pocket screw into the second joinery member33 a. Additional joinery members can be brought to conveyor 31 andjoined together to form various joinery assemblies.

[0041]FIGS. 2 and 3 schematically illustrate a fully automatedproduction line, but the apparatus and process of the present inventionalso may be used in a partially automated line or even a production linein which the joinery members are manually moved from one processingstation to the next. In such partial or manual production lines eachstation can be stationary and the jump stations eliminated.

[0042] It will be apparent from the description of the illustratedautomated production line, that one of the critical steps which must beperformed in order for the formation and joining together of joinerymembers in an assembly is the placement of fasteners, particularlypocket screws, in one of the joinery members as they pass along theline. Obviously, this step also is preferably preceded by an automationformation of a screw pocket in the joinery member. The screw pocketformation and fastener placement can be described in more detail byreference to FIGS. 3-7.

[0043] In FIG. 3, pocket forming apparatus 39 can be seen to be mountedto one or more rods or a guideway 53 for reciprocation along a side ofconveyor 31. End 54 of joinery member 33 will be clamped at a known,predetermined position relative to conveyor 31 by a stop or fence 34 atthe feed and indexing station 32. As end 54 moves into the pocketforming apparatus 39, a sensor 56 senses when the end is positionedproperly in pocket forming apparatus 39, at which point a clamp inpocket forming apparatus 39 clamps apparatus 39 to member 33, forexample, by clamping it against a support surface 57, with end 54against a vertically extending surface or stop 58. The pocket formingapparatus, therefore, is clamped to joinery member 33 and will travelwith it as conveyor 31 is advanced in the direction of arrow 37. Pocketforming apparatus 39 can be synchronously powered to move with conveyor31, or it simply be clamped so that conveyor 31, in effect, powersmovement of the pocket forming apparatus in the direction of arrow 59along guideway 53.

[0044] The form of pocket forming apparatus 39 employed in the presentprocess and apparatus preferably is one in which the pocket is routedand a fastener-receiving bore is drilled and both functions areincorporated into apparatus 39. The details of construction of such anapparatus are not critical to the fastener placement apparatus of thepresent invention, but they can be based upon my U.S. Pat. Nos.4,603,719 and 5,063,982, which are both incorporated herein in theirentireties by reference. Basically, pocketing forming apparatus 39 willform the screw pocket in a bottom or downwardly facing surface ofjoinery member 33 and drill the fastener-receiving bore from end 54 tothe routed pocket.

[0045] In FIG. 4, a router 61, which forms part of apparatus 39, isshown as being pivoted in the direction of arrow 62 to form pocket 63 ina downwardly facing surface 64 of joinery member 33. In a second step,shown in FIG. 5, drill 66 is advanced, as indicated by arrow 67, anddrills a fastener-receiving bore 68 from end wall or edge 54 of joinerymember 33 to pocket 63.

[0046] It also would be possible to form bore 68 parallel to the opposedside surfaces of member 33, instead of at a slight angle. If constructedin this manner, the pocket shape would also be changed (deepened) toenable the screw placement assembly to position the screw in a nearparallel orientation to the bore for insertion.

[0047] Once pocket 63 and connecting fastener bore 68 are formed, clamp55 of pocket forming apparatus 39 can be released to free the pocketforming apparatus for movement in the direction of arrow 69 alongguideway 53 back to the solid line “start” position shown in FIG. 3.This movement could be driven, for example, by a pneumatic cylinder (notshown). Similarly, router pivoting and drill reciprocation would also bepreferably pneumatically driven.

[0048] An additional optional step which can be performed once bore 68is drilled is to stabilize the core of the joinery member around bore68. For composite members, such as particle board, press board,agricultural board and the like, the cellulose particles inside theouter surfaces of the board may not be that strongly bonded together.Thus, an adhesive or binder material could be pumped under pressure intobore 68 to more strongly bind the particles exposed by drilling.Similarly, pocket 63 can be impregnated with a binder to stabilize thecore or particles exposed by routing. Such stabilization could occur ata separate processing station (not shown) between the pocket formingstation and fastener placement station, or be incorporated into thepocket forming station.

[0049] If a second or third screw pocket is to be formed in joinerymember 33, a second pocket forming apparatus can be positionedimmediately after pocket forming station 38. If the spacing alongconveyor 31 between pockets is sufficient, pocket forming apparatus 39can include side-by-side routers and drills so that a plurality ofpockets 63, and connecting fastener bores 68, can be simultaneouslyformed in a side-by-side fashion at a single, but wider, pocket formingjump station 38.

[0050] It also would be possible to form a pocket, position a screw orfastener in the pocket and thereafter form a second pocket, followed bypositioning of a second fastener, all while joinery member 33 is movingdown the production line on conveyor 31.

[0051] In order to facilitate subsequent joining to another joinerymember, it would also be possible to apply an adhesive to edge 54 of thejoinery member. Thus, a two sided adhesive tape could be placed on edge54 across bore 68. Pressure sensitive tapes and/or light-reactiveadhesives also could be used. In addition to facilitating assembly suchtapes or adhesives would assist in bonding the members together.

[0052] After pocket 63 is formed, joinery member 33 proceeds to fastenerpositioning apparatus 41, which is constructed in accordance with thepresent invention and is used to position or place a fastener, such as apocket screw, in the joinery member for subsequent use in fastening thejoinery member to another joinery member. FIGS. 6 and 7 schematicallyillustrate the fastener placement steps, while FIGS. 8-12 show thedetails of construction of the present fastener positioning device.

[0053] In FIGS. 6 and 7, joinery member 33 has been released from pocketforming apparatus 39 and advanced to positioning apparatus 41. Theposition of the joinery member on a supporting surface 71 will be sensedas the conveyor advances, and apparatus 41 is stationary at the start ofthe jump station. When properly positioned, a clamp 72 will clamp member33 to surface 71 with the end or edge 54 against vertically extendingsurface or fence 73. Positioning device 41 can then travel with conveyor31, as indicated by arrow 74 in FIG. 3, by reason of being pulled alongguideway 76 by conveyor 31 or by being synchronously powered to move atthe same rate as conveyor 31.

[0054] Once member 33 is clamped in position on surface 71, the fastenerplacement device moves a fastener from a feed magazine intofastener-receiving bore 68. In FIG. 6, a sequence of movement of apocket screw 74 from a feed magazine into bore 68 is shown. The pocketscrew first starts in a magazine position 74 a. Next, it is turned by anorientation assembly described below to position 74 b. The pocket screwis advanced to position 74 c, at which point it is gripped by a grippingassembly, which also will be described in more detail. The grippingassembly then raises the pocket screw upwardly into pocket 63 as shownby position 74 d. Finally, as shown in FIG. 7, the pocket screw isadvanced into bore 68 to position 74 e.

[0055] As will be seen from FIG. 7, and as is a feature of the apparatusand process of the present invention, the pocket screw, when in position74 e, will be entirely inwardly of the downwardly facing surface 64 ofmember 33. Moreover, the distal or pointed end 76 of the pocket screwwill be entirely inwardly of the edge or end 54 of joinery member 33.When placed in this position, joinery member can be moved alongfabrication support surfaces, such as conveyor 31, without pulling thepocket screw out of pocket 63 and bore 68. As will be described ingreater detail below, the pocket screw is held in position 74 e in bore68 by an interference fit between a shank portion of the pocket screwand bore 68. Such a fit prevents the pocket screw from falling out ofpocket 63, as well as preventing the screw from being jiggled orvibrated out of the pocket during subsequent manual or automatedmanipulation of joinery member 33.

[0056] Referring now to FIG. 8, the details of construction of apreferred embodiment of the joinery fastener positioning device 41 ofthe present invention can be described in more detail. Fastenerpositioning device 41 preferably includes a positioning surface orsurfaces 71 and 73 upon which joinery member 33 can be placed so thatfastener 74 can be moved to and mounted in bore 68 of screw pocket 63.It will be understood, however, that in the broadest aspect of thepresent invention, apparatus 41 could be used to position fasteners 74in a joinery member not having a screw pocket, for example, in a joinerymember having only a bore formed in a sidewall of the joinery member.The fastener would be merely placed in contact or engagement with thejoinery member sufficient to temporarily secure the fastener to thejoinery member for the next fastening step. Moreover, while thepreferred form of fastener is a pocket screw or wood screw, it will beunderstood that the present apparatus could be used to position othertypes of fasteners to a joinery member, such as a nail or a non-woodscrew.

[0057] Mounted to housing 81 of positioning device 41 is a fastener feedmagazine 82, which is formed for feeding fasteners to a grippingassembly or apparatus, generally designated 83. Most preferably,fastener feed magazine can be provided as screw shaker bowl feed device,which is commercially available from several courses including DesignTools, Inc. of Hickory, N.C. The feed assembly magazine includes avertically extending tube 82 having an internal diameter or bore 84dimensioned to slidably receive enlarged heads 86 of pointed fasteners74. Feed magazine 82 is provided with a pneumatic system which transfersscrews to tube 82 one-by-one from the orienting shaker bowl in a pointfirst orientation.

[0058] Gripping apparatus 83 is positioned to receive the fastenersone-by-one from feed magazine 82, and includes an orienting subassembly,generally designated 87, which re-orients the generally verticallyoriented fastener 74 a and to a near horizontal orientation 74 c forgripping.

[0059] Gripping apparatus 83 also is adapted to releasably gripindividual fasteners 74 in a manner causing pointed ends 88 to be heldin a known and controlled relation to the gripping apparatus so thatthey can be reliably positioned in the small diameter bore 68 in thejoinery member. As will be seen from FIG. 8, pointed end 88 of fastener74 in feed magazine or tube 82 is not in contact with the interior ofbore 84. Instead, tube bore 84 is contacted by enlarged head 86 andpointed end 88 of the fastener is free to be angularly displaced towardthe bore sidewall from the center line of the bore. Control of pointedend 88 is critical to placement of fastener 74 in the relatively smalldiameter bore 68.

[0060] Thus, an important feature of the present invention is thatfastener positioning device 41 of the present invention is formed tocontrol the position of pointed fastener end 88 so that it may beaccurately and reproducibly inserted into bore 68. The manner ofaccomplishing such controlled positioning of the pointed end 88 will bedescribed in more detail below.

[0061] Once fastener 74 is gripped by gripping assembly 83, the assemblyis further formed for movement between a fastener gripping position anda fastener placement position, all while the pointed end 88 of thefastener remains in indexed relation to the gripping apparatus. Fastener74, therefore, is moved from position 74 c to position 74 d, asindicated by arrow 89. While gripped in position 74 d, as can be seen inFIG. 6, pointed end 88 will be very closely aligned to the central axisof fastener-receiving bore 68 for insertion into the bore.

[0062] Fastener positioning device 39 also includes a placement assembly91 formed to urge fastener 74 from gripping apparatus 83 into contactwith joinery member 33 with pointed end 88 of the fastener in apredetermined known position in relation to the joinery member, namely,inserted down bore 68. Placement assembly accomplishes such positioningby pivoting of arm 92 about pivot point 93, as indicated by arrow 94.The result is to urge the fastener out of the gripping assembly and intobore 68, as shown in FIGS. 7 and 8.

[0063] Further details of construction of gripping assembly 83 can beseen from FIGS. 9-12. In FIGS. 9 and 10, an orienting subassembly 87 isshown which receives fasteners, pointed end first, from feed magazine82. The orienting assembly can advantageously be provided by a pair ofside-by-side, parallel and spaced apart, guide rails 101 which definetherebetween a fastener-receiving slot 102. Slot 102 is formed toreceive the screw body or shank 103 of fastener 74 and rails 101 arespaced closely enough together to support enlarged fastener heads 86thereon. Slot 102 between members 101 slidably receives body 103 of thefastener as it gravitates out of feed magazine 82. In the solid lineposition of fastener 74 a in FIG. 9, head 86 of the fastener rests onparallel spaced apart rails 101 in a near vertical orientation. Movablymounted to subassembly 87 is a slide member 104 which is coupled at end106 to an actuator 107, such as a pneumatic actuator. Opposite end 108of slide member 104 is preferably formed with a recess or as U-shapedend which engages head 86 of the fastener. Slide end 108 can be seen tohave a width dimension which is sufficient to span across 102 betweenthe two guide members 101 and slides along the upper surfaces of rails101.

[0064] Actuator 107 can reciprocate slide member 104, as indicated byarrows 109. When the actuator moves slide member to the right in FIG. 9,head 86 of fastener 74 is slid down the upper surface of rails 101.Mounted between rails 101 downstream of the fastener magazine 82 is are-orienting member 111, which preferably has an arcuate front uppersurface 112. As the fastener and head 86 are moved to the right, theshank or body 103 of the fastener engages surface 112 and tilts orrotates fastener 74 to position 74 b, as shown in broken lines in FIG.9. Slide 104 continues to advance fastener 74 until head 86 passesbeyond the ends 113 of rails 101. The fastener head drops down and thefastener is supported on the upper surface 114 of re-orienting member111.

[0065] As can be seen at the right end of FIG. 9 in broken lines, theend 108 of slide member 104 still engages the enlarged head 86 offastener 74. Further displacement of slide member 104 to the right,therefore, continues to slide fastener 74 along re-orientation member111 and to a position between a pair of spread apart gripping fingers121, which may be seen in FIGS. 11 and 12. Fastener 74 is supported onupwardly facing surface 114 of the re-orientation member 111 and onupwardly facing surface 122 of placement arm 92, which is aligned withand at the same level as surface 114. As the enlarged head 86 isadvanced by slide member 104 to the right, fastener head 86 reaches anotch 124 in arm 92, and fastener 74 is then oriented for gripping byfingers 121 in a predetermined known orientation, namely, as supportedbetween member 111 and arm 92. Moreover, gripping fingers 121 grip body103 of fastener 74 below head 86.

[0066] In FIGS. 11 and 12, gripping fingers 121 can be seen to becantilevered from pivotally mounted arm 127 and fingers 121 extendupwardly over a substantial distance so as to permit resilient outwarddisplacement of fingers 121 away from each other in the direction ofarrows 129 in FIG. 12. Bolts 128 can be used to secure fingers 121 toarm 127. In the relaxed condition, fingers 121 are spaced from eachother by a distance which is less than the diameter of fastener body orshank portion 103. In order to open the gripping fingers 121 to receivefasteners 74, a wedge element 125 is provided on orientation assembly 87which forces the two gripping fingers 121 outwardly from their relaxedcondition, as indicated by arrows 129. As arm 127 is pivoted downwardlyfrom support surface 71 to the position shown in FIGS. 8 and 11, a loweredge 130 of fingers 122 engages outwardly projecting wedge element 125on the end of subassembly 87 and forces the fingers apart so as topermit slide 104 to urge the fastener to the position shown in FIG. 8.When arm 127 starts to pivot upwardly, wedge 125 is disengaged and thefingers resiliently close and grip the fastener body at a position belowthe enlarged head, that is, they grip shank 103 of the fastener. Sincethe shank is being supported on surface 122 with the head 86 in notch124 at the time of upward motion and gripping, the pointed end 88 of thefastener is in a predetermined, known orientation when the fastener isgripped. Upon gripping by fingers 121, therefore, the fastener is heldin index relation to gripping assembly 83.

[0067] Once the fastener is gripped by fingers 121, actuator 131 is usedto pivot the arm 127 further about shaft 132 (FIG. 8) in an upwarddirection until the gripped fastener is positioned in pocket 63. Theprecise orientation of the fastener and its pointed end 88 is stillcontrolled by gripping fingers 121, and pointed end 88 of the fastenerwill be reliably aligned with fastener-receiving bore 68.

[0068] At this point, placement arm 123 (which also is carried by arm127 with fingers 121) is pivoted about pivot axle 93 by actuator 134.This drives arm 92 to the left, as indicated by arrow 136, which in turnurges fastener 74 from between the resilient fingers 121 and into bore68 to position 74 e, as shown in FIGS. 7 and 8. Shank 103 of thefastener then is urged into interference fit with bore 68 and thefastener is frictionally held in bore 68. Placement arm 92 can bepivoted back to the right and gripping arm 127 pivoted downwardly toopen or spread fingers 121 to receive the next fastener from thefastener re-orienting subassembly 87.

[0069] With the fastener frictionally held in bore 68 in a position sothat the head 86 is in pocket 63 upwardly of the surface 64 and thepointed end 88 is inwardly of the end or edge 54, the joinery member canbe moved automatically or manually to the next station for furtherprocessing, for example, for positioning abutting relation to anotherjoinery member and driving of the previously positioned fastener intothe other joinery member.

[0070] As will be understood, therefore, the positioning process of thepresent invention is comprised of the steps of feeding a fastener 74into a gripping apparatus 83, manipulating the fastener to a knownorientation; gripping body 103 of the fastener below head 86 while inthe known orientation with the gripping apparatus; moving the grippingapparatus to a fastener placement position 74 d proximate the joinerymember 33, while maintaining the fastener in the known orientation; anddisplacing the fastener from the placement position into contact, andpreferably interference fit 74 d, with the joinery member for securementthereto.

[0071] While as above noted, fastener 74 may take any one of a number ofdifferent forms and still be suitable for use with the process andapparatus of the present invention, it is preferred that fastener 74 beconstructed as shown in FIG. 13. Thus, fastener 74 can advantageouslytake the form of a monolithically formed pocket screw having a screwbody 103 with a head 86, a threaded end 141 terminating in point 88.Point 88, however, can also be a blunted point if the second memberreceiving the screw has a bore in it sufficient to allow the blunted endto enter the second member to a depth allowing the threads to engage andpull the screw into the second member. Shank 103 has a diameter which isgreater than the widest diameter of threaded end 141, which enhances theoverall fastener strength and predictably produces an interference fitwith the fastener-receiving bore 68.

[0072] Head 86 advantageously can be formed with a plurality of annularsteps 142 which have increasing diameter and are stepped outwardly fromshank 103. In the preferred form, at least three steps 142 are providedwith the first step being connected by an annular fillet 143 to shank103. Each annular step 142 includes a substantially 90° shoulder definedby a radially extending annular surface perpendicular to thelongitudinal axis 144 of the fastener and a cylindrical surface which issubstantially concentric to axis 144. Stepped head 86 slows pocket screw74 down as it engages the end wall of the pocket so that the threadswhich are screwed into the second joinery member do not spin orover-rotate when screwed in by a power screw driver. Steps 142 alsobetter fit the radius of the end wall of the pocket which is formed bythe router than a bevel headed wood screw so that more of the headengages the end wall of the pocket.

[0073] In the most preferred form, the thread pattern on end 141 is aself-tapping thread, and the threaded end 141 is connected to shank 103by an axially tapering section 146, which is tangential to both taperedthreaded end 141 and cylindrical shank 103. The fastener can include anend structure, such as a pocket 147 which is formed to receive astraight blade, a Phillips head screwdriver blade or, in the preferredform, a square pocket formed to receive a square headed screwdriver.

[0074] The fastener shown in FIG. 13 has a threaded end which can bescrewed into a second joinery member which is not previously drilled.Moreover, the tapered section 146 allows the fastener to be easily urgedinto interference fit with a bore 68 by a screw placement device 41 ofthe type described above. The relatively large diameter 103 of the shankcompresses bore 68 along its length due to the interference fit and hasthe strength to withstand such compression. Preferably, during drivingof the screw into a second un-drilled joinery member, shank 103 extendsacross the interface between the two joinery members so that the shearstrength is high between the two. Finally, square drive pocket 147allows substantial force to be applied to the pocket screw during thefastening process.

[0075] Referring now to FIG. 14, a preferred form of fastener-receivingbore 68 is shown, which is particularly well suited for use in materialsthat have a tendency to split. For most wooden joinery members, the bore68 from edge or end wall 54 to pocket 63 will be cylindrical. Compositematerials and some wood grain materials, however, will have a tendencyto split under the interference fit between fastener shank 103 and bore68. Accordingly, it is preferred in those instances where splitting canbe a problem that bore 68 be a non-cylindrical bore, and most preferablythat bore 68 be a slightly elongated in transverse cross section bore,with a large dimension extending along long axis 151 and oriented toextend across the thickness dimension, t, of end 54. The small dimensionof the elongated bore cross section is oriented along an axis 152perpendicular to the axis 151 and extending along a greater widthdimension, w, of member wall 54.

[0076] Fastener 74 will be selected such that shank portion 103 isgreater than the small dimension along axis 152 of the elongated bore68. This will allow the shank to temporarily secure the fastener inpocket 63, as above described. When the fastener is screwed into anotherjoinery member, the shank 103 will be pulled down the length ofelongated bore 68, tending to compress the material in opposeddirections along the axis 152. Since there is much more material in thewidth dimension, w, than in the thickness dimension, t, there will beless tendency for the joinery member to split under the compressiveaction of the shank on the material defining elongated bore 68. In fact,the larger dimension of bore 68 along axis 151 can be selected so thatthere is substantially no compression occurring in the thicknessdirection, t. This construction of fastener-receiving bore 68 willensure less splitting of the joinery pieces, and it can be accomplishedby slightly displacing drill 66 (using an oscillating mount) in avertical direction during the drilling step.

[0077] While an elongated cross section is shown for bore 68, it will beunderstood that broadly elongated bores can be advantageously used inother joinery applications. For example, the bore in the second joinerymember into which pocket screw will be screwed, also advantageously canbe an elongated bore oriented with the smaller diameter extending in thelarger dimension direction of the member and the larger diameter of thebore extending in the small dimension direction. The elongated crosssection obviously would be dimensioned based upon the thread diameter ofthe fastener, not the shank diameter.

What is claimed is:
 1. A joinery member with fastener pocket andfastener comprising: a joinery member having a fastener pocket formedtherein proximate an edge thereof, and a fastener-receiving boreextending from said pocket to said edge; and a fastener having a shankportion and being mounted in said pocket with said shank portion mountedin an interference fit with said bore to frictionally retain saidfastener in said pocket.
 2. The combination as defined in claim 1wherein, said fastener is a pocket screw and is mounted in said pocketin a position entirely inwardly of a surface of said joinery member inwhich said pocket is formed.
 3. The combination as defined in claim 2wherein, said screw is mounted in said pocket in a position entirelyinwardly of said edge having said bore therein.
 4. The combination asdefined in claim 1 wherein, said fastener is a pocket screw, and saidshank diameter is larger than a threaded end of said screw.
 5. Thecombination as defined in claim 1 wherein, said bore has an elongatedcross section.
 6. The combination as defined in claim 5 wherein, saidelongated cross section is oriented to extend with a small dimension ofsaid elongated cross section oriented in a direction of greatest lengthof said joinery member, and said shank portion is cylindrical with ashank diameter greater than said small dimension of said elongated crosssection.
 7. The combination as defined in claim 6 wherein, said shankdiameter is not larger in diameter than a large dimension of saidelongated cross section.
 8. The combination as defined in claim 1wherein, said joinery member is one of a wooden member, a compositewood-based member, a thermoplastic member and a composite wood andthermoplastic member.
 9. The combination as defined in claim 1 wherein,said pocket is an arcuate pocket increasing in depth in a directiontoward said edge and is formed in a surface of said joinery memberproximate said edge.
 10. The combination as defined in claim 1 wherein,said joinery member is formed with a plurality of pockets each having afastener-receiving bore extending from the pocket to an edge of saidjoinery member; and a plurality of fasteners mounted in said pocketswith a shank portion of each said fastener in interference fit with saidbore.
 11. The combination as defined in claim 10 wherein, said fastenersare each wood screws.
 12. A process for forming a pocket joineryassembly comprising the steps of: forming a fastener pocket in a surfaceof a joinery member proximate and spaced from an edge of said joinerymember; forming a fastener-receiving bore in said joinery member, saidbore extending between said edge and said fastener pocket; andthereafter mounting a joinery fastener having a pointed end in saidfastener pocket with said pointed end of said fastener extending intosaid bore and said fastener being secured in interference fit in saidbore.
 13. The process as defined in claim 12 wherein, said mounting stepis accomplished by mounting a screw having a shank portion with a shankdiameter larger than a diameter of said bore into said bore tofrictionally secure said screw in said bore by said shank portion. 14.The process as defined in claim 13 wherein, said mounting step isaccomplished by mounting a screw into said pocket with a threadedpointed end of said screw positioned in said bore inwardly of said edgeand a head end of said screw positioned inwardly of said surface. 15.The process as defined in claim 12 wherein, said step of forming afastener pocket is accomplished by routing a pocket into said surface,said pocket being progressively deeper in a direction toward said edge;and said step of forming a fastener-receiving bore is accomplished bydrilling said bore from said edge toward said pocket.
 16. The process asdefined in claim 12 wherein, said steps of forming a fastener pocket,forming a fastener-receiving bore and mounting a joinery fastener areall accomplished while said joinery member is being advanced along aprocessing line.
 17. The process as defined in claim 16 wherein, saidstep of forming a fastener pocket is accomplished by rotating a routerinto engagement with said joiner member while said router is advanced ata rate of advancement of said joinery member along said processing line.18. The process as defined in claim 16 wherein, said step of forming afastener-receiving bore is accomplished by advancing a drill into saidjoinery member from said edge in an inwardly direction while said drillis advanced at a rate of advancement of said joinery member along saidprocessing line.
 19. The process as defined in claim 16 wherein, saidstep of mounting a joinery fastener is accomplished by positioning apocket screw in said pocket with a threaded end pointed aligned withsaid bore, and thereafter pressing said pocket screw into said pocket,with said positioning and pressing steps being accomplished while saidjoinery member is being advanced along said processing line.
 20. Theprocess as defined in claim 12 wherein, said step of forming a fastenerpocket, forming a faster-receiving bore and mounting a joinery fastenerare all accomplished by moving the joinery member from one fixedprocessing station to another fixed processing station.
 21. The processas defined in claim 12, and the steps of: after said mounting step,positioning said joinery member in abutting relation to another joinerymember, and securing said joinery member to said another joinery memberby driving said fastener into said another joinery member.
 22. Theprocess as defined in claim 12, and the steps of: after said mountingstep moving said joinery member with said fastener mounted thereto froma fastener placement station to an assembly station; thereafterassembling said joinery member to another joinery member; and thereafterdriving said fastener into said another joinery member in order tosecure said joinery member to said another joinery member.
 23. A pocketscrew comprising: a monolithic screw body having a head, a shankextending away from said head and a threaded pointed end extending awayfrom said shank, said shank having a shank diameter greater than awidest diameter of said threaded end, and said head being formed with aplurality of annular steps of increasing diameter stepping outwardlyfrom said shank.
 24. The pocket screw as defined in claim 23 wherein,said head is formed with at least three annular steps of increasingdiameter.
 25. The pocket screw as defined in claim 24 wherein, a firstannular step is connected to said shank by an annular fillet.
 26. Thepocket screw as defined in claim 25 wherein, each annual step includes asubstantially 90 degree shoulder defined by a radially extending annularoriented surface substantially perpendicular to a longitudinal axis ofsaid screw and a cylindrical surface substantially concentric to saidlongitudinal axis.
 27. The pocket screw as defined in claim 23 wherein,said threaded pointed end is formed with a self-tapping thread.
 28. Thepocket screw as defined in claim 23 wherein, said threaded end isconnected to said shank by an axially tapering section.
 29. The pocketscrew as defined in claim 28 wherein, said tapering section istangential to both said threaded end and said shank.
 30. A joinerymember comprising: a member having a small dimension in one plane and alarger dimension in another plane substantially perpendicular to saidone plane; and a fastener receiving bore with an elongated transversecross section formed in said member with a large dimension oriented toextend substantially in said one plane and a small dimensionsubstantially perpendicular to said large diameter and oriented toext4end substantially in said another plane.
 31. The joinery member asdefined in claim 30 wherein, said member has a thickness dimension lessthan a width dimension at an edge thereof, said bore extends from apocket proximate said edge to said edge, and said large dimension ofsaid elongated bore is oriented to extend across said thicknessdimension.
 32. The joinery member as defined in claim 31, and a screwhaving a cylindrical shank with a shank diameter greater than said smalldiameter of said bore and about equal to said large dimension of saidbore, said screw being mounted in said screw pocket with said shankpositioned in said bore.
 33. A joinery fastener positioning devicecomprising: a positioning surface for positioning a joinery member forplacement of a joinery fastener; a feed magazine formed for feedingpointed joinery fasteners to gripping apparatus; a gripping apparatuspositioned to receive fasteners from said feed magazine, said grippingapparatus being further adapted to releasably grip individual fastenersin a manner causing the pointed end of said fastener to be held in aknown and controlled indexed relation to the gripping apparatus, andsaid gripping apparatus being movable between a fastener grippingposition and a fastener placement position while said pointed end ofsaid fastener remains in indexed relation to said gripping apparatus;and a fastener placement assembly formed to urge said fastener from saidgripping apparatus into contact with said member with said pointed endof said fastener in a predetermined known position in relation to saidmember.
 34. The joinery fastener positioning device as defined in claim33 wherein, said feed magazine is a vertically extending bore having adiameter slidably receiving enlarged heads of said fasteners.
 35. Thejoinery fastener positioning device as defined in claim 34 wherein, saidbore is provided by a vertically extending tube member with saidfasteners being gravity biased for feeding of fasteners point-first tothe gripping apparatus.
 36. The joinery fastener positioning device asdefined in claim 33 wherein, said gripping apparatus includes a fastenerorienting assembly formed to orient said fasteners for gripping inindexed relation.
 37. The joinery fastener positioning device as definedin claim 36 wherein, said orienting assembly receives said fastenersfrom said feed magazine and orients said fasteners for gripping belowheads thereof by said gripping apparatus.
 38. The joinery fastenerpositioning device as defined in claim 37 wherein, said orientingassembly receives said fasteners point-first in a near verticalorientation from said feed magazine and rotates said fasteners to a nearhorizontal orientation for gripping below the heads of said fasteners bysaid gripping apparatus.
 39. The joinery fastener positioning device asdefined in claim 38 wherein, said orienting assembly includes a pair ofspaced apart guide rails slidably receiving shank portions of saidfasteners therebetween and supporting heads of said fasteners thereon,and includes a movable slide member positioned to slide along a topsurface of said guide rails and movable therealong into engagement withsaid heads of said fasteners, and said orienting assembly furtherincluding a fastener body engaging member below said guide railslongitudinally and positioned along said rails downstream of a positionat which said fasteners are received by said guide rails from said feedmagazine, and said slide member and said body engaging membercooperating to rotate said fasteners upon movement of said slide memberalong said top surface of said guide rails.
 40. The joinery fastenerpositioning device as defined in claim 33 wherein, said fastenerplacement assembly includes a movable arm formed for movement between aposition permitting gripping of said fasteners by said grippingapparatus and a placement position forcing said fastener from saidgripping apparatus and into contact with said joinery member.
 41. Thejoinery fastener positioning device as defined in claim 33 wherein, saidgripping apparatus is movable between a fastener gripping positionreceiving fasteners from said orienting assembly and a fastenerplacement position in which said fasteners are positioned in afastener-receiving pocket in said joinery member with the pointed endoriented for insertion into a fastener bore extending from said pockettoward an edge of said joinery member.
 42. The joinery fastenerpositioning device as defined in claim 41 wherein, the fastenerplacement assembly is formed to urge said fasteners from the grippingapparatus into said fastener bore.
 43. The joinery fastener positioningdevice as defined in claim 33 wherein, said gripping apparatus includesa pair of opposed resiliently displaceable gripping fingers cantileveredfor resilient outward displacement from a relaxed condition spaced apartless than the diameter of said fastener body to a spread position forreceipt of fasteners therebetween; and a wedge member carried by saidfastener placement assembly and positioned to engage said grippingfingers and separate said gripping fingers to said spread position forreceipt of said fasteners and positioned to disengage from said grippingfingers upon movement of said fastener assembly to permit gripping ofsaid fasteners.
 44. The joinery fastener positioning device as definedin claim 43 wherein, said fastener placement assembly is provided by apivotally mounted arm formed to move between said gripping fingers andengage the heads of said fasteners to force said fasteners from betweenthe resilient gripping fingers and into contact with said joinerymember.
 45. A process for positioning a fastener having a head, a bodyand a distal end for securement to a member comprising the steps of:feeding said fastener to a gripping apparatus; manipulating saidfastener to a known orientation; gripping said body of said fastenerwhile in said known orientation with said gripping apparatus; moving thegripped fastener to a fastener placement position proximate said memberwhile maintaining the fastener in the known orientation; and displacingsaid fastener from said placement position into contact with said memberfor securement thereto.
 46. The method as defined in claim 45 wherein,said feeding step is accomplished by gravity feeding said fastener froma tubular feeding magazine.
 47. The method as defined in claim 45wherein, said manipulating step is accomplished by reorienting saidfastener on guide rails to said know orientation.
 48. The method asdefined in claim 45 wherein, said gripping step is accomplished bygripping said body between spaced apart fingers resiliently biasedtoward each other.
 49. The method as defined in claim 45 wherein, saidmoving step is accomplished by pivoting said gripping apparatus to saidfastener placement position in which said fastener is in a pocket formedin a joinery member.
 50. The method as defined in claim 45 wherein, saidfastener has a pointed threaded end and said member is a joinery member,and said displacement step is accomplished by inserting said pointed endof said fastener into a bore in said joinery member.